ML19261E949
| ML19261E949 | |
| Person / Time | |
|---|---|
| Site: | Oconee, Crane  |
| Issue date: | 12/05/1969 |
| From: | Oller R, Thornburg H US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19261E944 | List: |
| References | |
| B&W-69-08, B&W-69-8, NUDOCS 7910171001 | |
| Download: ML19261E949 (10) | |
Text
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U. S. ATOMIC ENERGY CCMMISSICN REGION III DIVISION OF CCMELIANCE Vendor Inspection Report j
FWR Vessels
//
Vendor:
Babcock & '4ilcox Co=pany Mt. Vernon, Indiana Report No:
B&W 69/*
Components Inspected For:
Ocenes 1 (50-269)
Three Mile Island Un.c 1 (50-289)
Dates of Inspectien-November 12-14, 1969 hd, V V
Inspector:
R. E. Oller Metallurgical Engineer December 5, 1969 Licensee Representatives:
J. M. Curtis - Duke Pcwer Company Ncne - Metro Ediscn of Pennsylvania l
Reviewed By:
F.
D. Thornburg(
Sr. Reac*.or Inspector December 5, 1969 Proorietary Information:
Eatire Report Licensee Application Requirements-Oconee 1 FSAR - Section III, ASME Cc!e plus Summer Addendtm 1969. per CO:II Three Mile Island Unit 1 FSAR - Section III, ASME Ccde, 1965, per CC:I Summary Final review of MIR's, heat treatment data, contract variaticas, and RT films for Oconee 1 showed them to be in accordance with Sectica III, ASME Code, and AS TM specifications.
The tcp and bottem head domes had " cut of ccde mismatches which were corrected by weld metal buildup and 3:1 tapering in acccrdance with Secticn III, ASME Code.
Ihe Oconee 1 vessel was beia; prepared for hydrcstatic testing during the C0 inspection. Babccck & '.ialecx's (3&W) S-173 Standard Specificaticn for Hydrostatic Testing met tne intent of the code, but was not in accordance with Sectica I!!, Far. N-712.3, in that it specified inspection at "Specified Hydrostatic Iest Fressure" wnich censtituted poor 1483 296 7910174DO.f
. 2-Summary (continued) safety practice.
Mr. Manoll stated he would discuss this defictency with Barberton Engineering. The applicant's representative, Mr. Curtis, informed CO:III by telephone on November 29. 1969, that he had talked ec the Hartford Insurance inspector, prior to the test, who stated that the test would be conducted according to the code.
Mr. Curtis stated further that the hydrostatic test was successfully completed on November 27, 1969, and that he would make a post hydro audit of test reccrds and MT inspection results.
We find that the Oconee 1 reacter vessel has been fabricated, tested, and inspected in accordance with Secticn III, ASNE Code based on the fcilowing:
1.
Compliance's review of material, fahrtcation, and inspectic:
rc-cedures and records showed them tc be in acccrdance with coues, standards, and specifications.
2.
Third party inspection was performed by Hartford Steam Bctler and Insurance Company during fabrication, testing, inspecticn, and N stamp certification.
3.
The applicant performed periodic audit of design, fabricatica, testing, and inspection, including post hydre inspectien-B&W is in the process of negotiating subcentracting of varicus nuclear steam system compenents (subsequent to Cconee 1) and relocating others to different B&W manufacturing facilities.
(Sectict II.A.)
Material records en the Three Mile Island Unit I reactor vessels were incomplete and tot readily traceable at Mt. Vernon due to Barberten's delay in transmitting them.
CO:III will review the complete records at a s_e-sequent inspection.
This is a ccndition ccmccr to vessels manufact red by E&W for B&W built facilities.
B&W was surveyed by the ASME N stamp team in March and September 1969 and has received three N stamps fer nuclear vessels, nuclear parts, and nuclear piping.
Details I.
Scone of Inspection On November 12-14, 1969, an announced vendor inspection was made of B&W, Mt. Vernon, Indiana. by R. E Oller, Metallurgical Engineer, CO.III.
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. Details (continued)
The purpose of the inspection was twofold.
i.e.,
(1) to complete the review of material records, final stress relief records, x-ray films, and hydrostatic test procedure for the Oconee 1 reacter vessel /; and (2) to make an initial audit of material record for Three Mile Island reactor vessel.
The following persons were contacted during this inspection:
R. Mancil, Resident Engineer, B&W, NFGD-QA, Lynchburg F. S. Kane, Nuclear Csapanents Specialist, E&W, CNC, Mt. Vernen D. J. Shepherd, Assistant QC Engtneer, B&W, Mt. Vernen G. Maher, Supervisor of Records Production Contrcl, B&W, Mt. Vernen W. Buskey, QC Manager, B&W, Mt. Vernca J. Bryant, Project Engineer, B&W Nuclear Steam Supply Systems, Mt. Vernon D. Campbell, Chief Inspector, QC Department, B&W Mt. Vernen W. Murphy, Chief Rigger, in charge of hydrostatic test, Oconee 1, B&W, Mt. Vernon R. Mason, Resident Inspector, Hartfcrd Insurance Ccmpany J. M. Curtis, QA Engineer, Duke Power Company II.
Results of Insoection A.
Oconee Unit 1 Reactor Vessel 1.
Records a.
MTR's Balance of MIR's was reviewed for tcp and bottom head domes (Mk24 and Mk 6 compenents, respectively),. upper half of nozzle course forging (Mk 8)
Icwer center course vessel shell (Mk A-1), and inlet and c_tlet circulation nozzles (Mk 18 and Mi 19, respectively)
These MIR's were complete and test data was in accordance with A-302, B mcdified materia! and Section II~, ASME Ccde 1/ CO:III Report No. 269/69-a.
D"D DIF@flI
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=
Details (continued) for chemical compcsitica, physical prcperties, impact values, heat treatment, and nondestructive testing. Scme delay was incurred in finding portions of the reccrds which required getting copies by telephetc transmittal frem Barberton.
The CO inspector noted in the exit interview that these records had been requested from Barberton in April.
b.
Variation Notices In-process Contract Variation Nccices (CVN) accumulated since April 1969 were reviewed. All CVN's with supporting reject inspection tickets and final clearance tickets were accounted for.
CV records ccvering Mk A-24 closure head assembly, Mk B-8 shell flange-nczzle course-upper shell course assembly, Mk B-1 intermsdiate shell assembly, Mk A-36 lower head assembly, and C-8 circle seam jcining the intermediate shell to nozzle ccurse, were ccmplete.
The C0 inspector noted that VN 50249 fcr the ;pper 5.ead dome, and VN 50353 for the lower head dome, detal'.ad out of ccde mismatches cf head demes requirir.g weld metal buildup aid 3:1 tapering to bring them back into code conformity.
Both repairs were made and NDT inspected in accordance with Secticn III, ASPE Ccde.
This cendition was discussed with Mr. Buskey during tne exit interview.
c.
Final Stress Relief The furnace charts covering the final strass relief of tne 0
vessel shcwed the vessel was st rass relieved at 1125 F
+ 25 for 15 hours1.736111e-4 days <br />0.00417 hours <br />2.480159e-5 weeks <br />5.7075e-6 months <br /> in acccrdance wi:n Sec:ler !!! ASMI
~
Code.
d.
Radiograohs Ten out of a total of 66 dcuble radicgrapa films for the circle seam C-8 Jcining Mk B-8 assembly ec Mk B-1 assembly were examined. The technique was good as evidenced by good centrast and a penetrameter sensitivicy of less than
- 17.. No weld dafects were cbserved.
2.
Hydrostatic Test On arrival at Mt. Vernon, the CC irspec:cr observed the Oconee l reactor vessel was being prepared for hydrestatic testing in 1483 299
h il dOuu G m a d\\_
,3, Details (continued) a vertical position on the shop floor. Cleaning, hydro plug installation. and filling to nozzle level were complete.
The closure head was being posittened prior to turn-dcwn of studs and tensioning. Sampling cf the demineralized hydro test water was in process.
Pressure gauges had been calibrated The CO inspector learned that Mr. W. Murphy, Chief Rigger, Production Department, would supervise the hydre test.
Inspections wculd be made by D. Campbell. Chief Inspector, QC Department, and R. Mason, Inspector, Martford Steam Sc11er Insurance.
Mr. Curtis, Duke Pcwer Ccapany (DP) wculd witness the test.
Mr. W.
Buskey, QC Manager, had overall responsibility fcr the test.
At this time the C0 inspector found that a final Oconee procedure for cleaning-tensioning and ' hydro test were not at the test area.
B&W Standard Procedure S-178, Hydrostatic Testing of Nuclear Vessels, rev. 2, dated June 22, 1968, and three-pass tenstening data sheets were available.
Mr. Curtis (DP) told B&W he wanted the ccmplete procedure at the test area before pressurizaticn and B&W stated they wculd ccmply with his request.
The CO inspector notea that the S-178 procedure specified ptessure levels for inspection which included inspection at specified hydrcstatic pressure. Inis inspection point is not in accordance with Section III, AShE Code, Par. N-712.3.
The CO inspecter advised Messrs.. Cur tis, Busrey, Kane, and Mancli during the inspectica and exit interview.trat this practice, in addttter to not being in accordance with the code, also vic ' ated gcod safe ty pract _ce.
Mr. Mancil (E&W-NPGD), stated the S-178 specification was issusd by Barbertcn, CNC Engineering, and that Mt. Vernen, CNC, was cbligated to fellow it.
However, he stated he would review the matter with Barbercon Engineering.
Mr. Curtts. DF, advised the inspector by telephone on November 29, 1969, tnat he had talked with R. Mason, Hartford Insurance inspector, prior to the hydrostat'c test.
Mr. Mascn stated he would perform the inspection in accordance w1:5 Sectica Code.
W On December 1, 1969, Mr. Curtis advised tne tnspectcr by telephone that due to hydrostatic plug leakage. the test was delayed until November 27 1969, at which time the 1483 300
D""D 9.* fl$iQf a
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3 _oo Details (continued) hydrostatic test and inspection was successfully performed at specified pressure of 3125 psig and 95 F (NDT + 600F).
He stated further that DP would examine hydro test and post hydro MI records and make an inspection of the vessel prior to shipment.
Mr. Buskey stated that provisions had been made for B&W to inspect the vessel and parts after receipt at the site and that a written procedure covering this inspection was in existence.
3.
Other Items Discussed a.
Manufacturing Relocation of Components Through discussion, the inspector learned that B&W is currently negotiating subcontracting of certain components and relocating manufacture of others to various B&W plants for units subsequent to Oconee 1.
The B&W loca-tions are Madison, Indiana, and Canton, Ohio, for pressurizers; Earberton for steam generators and reactor nozzles; Mt. Vernon, Indiana for reactor vessels and primary system piping.
Negotiations are incomplete for subcontracting components as - f-1-o o d ing tanks and core internals.
Mr. Manoll stated B&W has purchased the old Bliss Manu-facturing plant in Canten, Ohio, for conversion to nuclear component work.
b: lEthBSSFIM 13A i&H. BaF4 E8=4EROi4EE84 Mr. D. J. Shepherd, Assistant QC Engineer, stated that a new inspection and test data computer punch form was being put into use. All inspection and test data developed for each component during manufacturing sequences will be coded and stored in the Barberton computer for record and quality control evaluation. This system will provide rapid feedback and replace the present inspection upgrading inspection sheets.
B.
Three Mile Island Reactor-Vessel 1.
Backaround Information This inspection was the first Compliance audit of the Ihree Mile Island (Metro Edison of Pennsylvania) reactor vessel.
I483 40I
. Details (continued)
The vessel is a 171" ID PWR, designed by B&W, and is similar in size and design to Oconee 1 except for deletica of the head transitien ring forging, and the nozzle course forging being chamfered to match the center plate course. Overall length is 40' 10-3/4" including closure head CRD support housings and lower head instrumentation nozzles.
2.
Shop Inspection The inspection showed the vessel was currently in an advanced manufacturing status cenststing of three assemblies:
(1) bottcm head and middle shell, (2) nozzle course and flange with nozzles installed, and (3) closure head with flange. Six-wire cladding af bottom head and middle shell was complete and appeared smooth and free of defects. The back cladding of the circle seam was in process of being PT examined.
Installation of the in-core instrument tubes in the bottem head was complete.
Single wire cladding in the nozzle shell course was complete and appeared to be of good quality. The closure head and flange assembly had the CRD nozzle heles in a rcugh bored condition and the dome ID was unclad.
3.
Records Audited MTR's for the vessel components were reviewed with Mr. G. Maher.
Records were poorly organized and difficult to correlate with the components which caused a considerable. loss cf the inspec-tor's time.
Several MIR's were unavillable (still at Barberton) and others lacked complete data en physical properties.
Mr. Maher's only explanation was that Barberton had not trans-mitted the records to Mt. Vernon.
Some component MIR's were complete and met specifications, others were not complete or were unavailable at Mt. Vernon.
Status of MTR's were as follows:
a.
Complete MTR's (1)
Shell flange (Mk 7) from U. S. S teel Company.
( 2)
Nozzle shell course upper and lower forgings (Mk 36 and 87, respectively) from Ladish Company.
1483 402 s
. Details (continued)
(3) Lower head ring forging from Bethlehem Steel Ccmpany.
b.
Incomplete MIR's These MTR's were incomplete in various test data aspects as physical properties, Charpy V impact properties, heat treatment, end magnetic particle testing. These tests, in some cases,would be performed by B&W, Barberton, while others should have been performed by the supplier.
(1)
Closure head dome (Mk 24). The plate material was furnished by Lukens Steel and formed at Barberton.
(2)
Closure head flange (Mk 22). This farging received from Bethlehem Steel.
(3) Middle shell course (Mk A-1 for twoplates) from Lukens S teel.
(4) Lower shall ecurse (Mk A-2 for twa plates) frem Lukens Steel.
(5)
One inlet circulation nozzle (Mk 18) from Bethlehem Steel.
c.
Unavailable MTR's (1) 'Three inlet circulation nozzles (Mk 18).
(2)
Two outlet circulation nczzles (Mk 19).
(3)
Two core flooding aczzles (Mk 17).
(4)
Lower head deme (Mk 6).
The inspector indicated that the present state of the MTR's did not permit a meaningful evaluation of the quality of the pressure vessel materials.
In addition, B&W was informed that all records associated with the Three Mile Island pressure vessel would be reviewed during subsequent inspecticns, viz.,
CVR's, Heat-Treatment Charts, and radiograph films and MIR*s.
The matter of deficient MTR's was reviewed in the exit interview.
1483 303
, Details (continued)
C.
Exit Interview An exit interview was held with Messrs. Buskey, Kane, and Manoll of B&W, and Curtis of DP.
No representative was present frem Metro Edison of Pennsylvania during the exit interview or the inspection, althcugh the applicant had been notified in advance cf the C0:III inspection.
The inspector reviewed the following items:
1.
Final review of Oconee 1 records showed them te be complete and correct, however, records were still net centrally located. It was noted that this ccnditica had been ncted by the inspector previously in April 1969.
Mr. Mancil stated that prior to shipment of the vessel, all re crds would be accumulated in a package and verified prter to shcp release.
Mr. Buskey stated he was in the prccess of reviewing all records related to each competent and specific weld.
2.
The inspector noted that a formal procedure fcr Ocenee 1 vessel cleaning, filling, closure, and hydrostatic test had not been at the test area prict to start of work.
Mr. Kane stated that i= mediate action wculd be taken to get tht procedure to the test area.
3.
The inspector noted further that B&W Standard S-178, althcugh meeting the intent of the code, was not in accordance with Section III, ASME Code in that it specified inspection at specified hydrostatic pressure, which corstituted pccr safety practice.
Mr. Mano11 stated he would discuss this matter with Engineering in Barberton.
4 In regard to the Three Mile Island reccrds, the inspecter stated material records were inccmplete, others missing, and correlation of records with components was difficult.
It appeared that there was a problem connected with the transfer of records from Barberton to Mt. Vernon. The inspector also noted that CO would audit the complete records during the next inspection.
Mr. Suskey e <plained that CNC at Barberten performed all procurement and that Mt. Verten had no control over purchasing.
he furtner stated tnat the difficulty in correlation of records and compenent Mk numbers was due to every item being identified by permanent serial and heat numbers 304
. Details (continued) rather than drawing mari numters.
E&W.s new changing the drawing idenr.ificaticn mark t'.mber to a ccmbi.ad part-mark number which will prevent duplication of identift:9 tion and provide improved correlatict with vessel components.
During the exit interview the inspector learned : hat Mt. Vernon was surveyed by the ASME team in Maren and September of 1969. He was snown three nuclear stamps. :.e N (for vessei), N?! (for nuclear parts),
and NP (for nuclear piping)
The inspector questiened the cause of cut of ccde mismatch of the tcp and bettcm vessel head dcmes.
Mr. Bus't ey exp lair.ed that enis was inherent in the ferming operatica due to the large size and tnickness of the plate. With the present state cf techtclegy at E6W and cther fabricators, he did not think this difficulty could be avoided.
dowever, the weld buildup and 3: 1 taper repair had brcugnt the assembly witht: ccde requ rements.
The inspector thanked E&W fcr their cecperat;en m
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